Evaluation of Titanium Alloys Fabricated Using Rapid Prototyping Technologies-Electron Beam Melting and Laser Beam Melting.

Mari Koike,Lawrence E Murr,Sara M Gaytan,Preston Greer,Edwin Martinez,Toru Okabe,Kelly Owen,Guo Lilly

doi:10.3390/ma4101776

Abstract

This study characterized properties of Ti-6Al-4V ELI (extra low interstitial, ASTM grade 23) specimens fabricated by a laser beam melting (LBM) and an electron beam melting (EBM) system for dental applications. Titanium alloy specimens were made into required size and shape for each standard test using fabrication methods. The LBM specimens were made by an LBM machine utilizing 20 µm of Ti-6Al-4V ELI powder. Ti-6Al-4V ELI specimens were also fabricated by an EBM using 40 µm of Ti-6Al-4V ELI powder (average diameter, 40 µm: Arcam AB®) in a vacuum. As a control, cast Ti-6Al-4V ELI specimens (Cast) were made using a centrifugal casting machine in an MgO-based mold. Also, a wrought form of Ti-6Al-4V ELI (Wrought) was used as a control. The mechanical properties, corrosion properties and grindability (wear properties) were evaluated and data was analyzed using ANOVA and a non-parametric method (α = 0.05). The strength of the LBM and wrought specimens were similar, whereas the EBM specimens were slightly lower than those two specimens. The hardness of both the LBM and EBM specimens was similar and slightly higher than that of the cast and wrought alloys. For the higher grindability speed at 1,250 m/min, the volume loss of Ti64 LBM and EBM showed no significant differences among all the fabrication methods. LBM and EBM exhibited favorable results in fabricating dental appliances with excellent properties as found for specimens made by other fabricating methods.

Highlights

Rapid prototyping and manufacturing (RP or RPM) is an emerging technology that has revolutionalized product development and fabrication [1]
Compared to the conventional material forming processes, the part is fabricated by additive processes through a gradual-building of solid material from powder layers to the required shape from profiles created using CAD, X-ray computer tomography (CT), magnetic resource imaging (MRI) scanning, etc
A number of articles have been published with respect to the capabilities of these methods, the mechanism of the additive fabrication processes, properties of products made with these technologies, and applications

Summary

Introduction

Rapid prototyping and manufacturing (RP or RPM) is an emerging technology that has revolutionalized product development and fabrication [1]. Compared to the conventional material forming processes, the part is fabricated by additive processes through a gradual-building of solid material from powder layers to the required shape from profiles created using CAD, X-ray computer tomography (CT), magnetic resource imaging (MRI) scanning, etc. Since this method requires no fixtures and tooling, a considerable reduction in the cost and lead time can be achieved. The LBM process is commonly called selective laser melting (SLM) At first, this method was developed to produce industrial parts has been considered as an economical processes for the fabrication medical and dental prostheses.

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